ITR WindowWasher User manual

The WindowWasher™ by ITR
Installation and
Operating Manual
Diesel Fired Continuous Output
Window Cleaning Water Heater

Copyright © February 2012
International Thermal Research
INCANADA: INTHEUNITEDSTATES:
2431 Simpson Road 11915 NE 56th Circle, Suite B
Richmond, BC, Canada V6X 2R2 Vancouver, WA, USA 98682
Tel: [phone] or 604-278-1272 Tel: [phone] or 360-993-4877
Fax: [phone] Fax: [phone]
Email: [email protected] Email: [email protected]
Website: http://www.itrheat.com
All rights reserved. No part of this manual may be reproduced or
transmitted in any form by any means, electronic or mechanical,
including photocopying and recording, information storage,
retrieval, or transmission, without permission in writing from
International Thermal Research
Right to Modify:
Due to our commitment for quality and ongoing product
improvement, ITR reserves the right to modify or change
without notice, any materials, applications, equipment,
accessories, and/or prices. All measurements and weights are
approximate.

Table of Contents
iv WindowWasher by ITR Installation Manual
Table of Contents
Section 1, Overview .................................................. 1-1
1.1 Unpacking The WindowWasher™ by ITR...........1-2
1.2 Protect Your Warranty...................................1-2
1.3 The WindowWasher™ by ITR Features.............1-3
1.4 Critical Factors .............................................1-4
1.5 Equipment, Tools and Skills............................1-4
1.6 Testing and Inspection ..................................1-5
Section 2, Mounting - The WindowWasher™ ............ 2-1
2.1 Before You Begin..........................................2-1
2.2 Your Mounting Location .................................2-2
2.3 Procedure....................................................2-4
Section 3, Installing the Exhaust System .................. 3-1
3.1 Before You Begin..........................................3-1
3.2 Mounting Location ........................................3-1
Recommended Exhaust Outlet Locations............ 3-1
Recommendation for Installation ...................... 3-2
What NOT to Do............................................. 3-4
3.3 Procedure....................................................3-4
Section 4, Installing the Fuel System ........................ 4-1
4.1 Before You Begin..........................................4-1
4.2 Fuel System Operation ..................................4-1
Recommendation for Installation ...................... 4-1
4.3 What NOT to Do ...........................................4-2
4.4 Procedure....................................................4-3
Section 5, Wiring the Electrical System..................... 5-1
5.1 Before You Begin..........................................5-1
5.2 12 VDC .......................................................5-1
5.3 Remote Operating Panel Cable........................5-2
5.4 Main Electronic Control Board.........................5-2
5.5 What NOT to Do ...........................................5-3

Table of Contents
International Thermal Research International Thermal Research Ltd. February 2012
Section 6, Plumbing the System ................................6-1
6.1 Before You Begin ......................................... 6-1
6.2 Plumbing Installation .................................... 6-2
6.3 What NOT to Do........................................... 6-4
6.4 Installation Procedure................................... 6-4
Section 7, Operating The WindowWasher™ by ITR ....7-1
7.1 Operating Instructions for
The WindowWasher™ by ITR ......................... 7-1
7.2 Turning the Power to
The WindowWasher™ by ITR ON .................... 7-2
7.3 Activing the Burner (Primary) ........................ 7-2
7.4 Functions of the Remote Operating Panel......... 7-2
7.5 Functions of The WindowWasher™ by ITR
Control Panel............................................... 7-3
7.6 Maintenance................................................ 7-5
7.7 Protect The WindowWasher™ by ITR™............ 7-8
7.8 General Troubleshooting ............................... 7-8
Section 8, Warranty and Service................................8-1
8.1 Warranty .................................................... 8-1
8.2 Installations ............................................... 8-1
8.3 Limited Warranty ......................................... 8-2
8.4 Owner’s Responsibility .................................. 8-2
8.5 Not Covered Under Warranty ......................... 8-3
8.6 Customer Service Calls ................................ 8-4
8.7 Returns ...................................................... 8-4
8.8 Telephone Service........................................ 8-5

Table of Contents
vi WindowWasher by ITR Installation Manual
List of Figures
Figure 1-1 Window Washer .........................................1-1
Figure 2-1 Dimensions ...............................................2-3
Figure 2-2 Location of Mounting Brackets
Insets: Bracket/Nut/Bolt Configurations........2-4
Figure 3-1 Installing the Exhaust System (Up Exhaust)...3-4
Figure 5-1 System Wiring ...........................................5-3
Figure 6-1 Plumbing Fittings........................................6-1
Figure 7-1 The WindowWasher™ by ITR – Fittings..........7-1
Figure 7-2 Remote Operating Panel..............................7-3
Figure 7-3 The WindowWasher™ by ITR – Control Panel..7-4

Table of Contents
International Thermal Research International Thermal Research Ltd. February 2012

International Thermal Research 1-1
Overview
Thank you for purchasing The WindowWasher™ by ITR for portable hot
water window cleaning.
This section describes features of The WindowWasher™ by ITR and
covers critical information you need to know before beginning the
installation, including how to protect your warranty, and tools and
equipment needed.
Figure 1-1
Section
1
Some of the figures
in this manual
represent a typical
installation, but
other configurations
or methods may be
acceptable. If in
doubt, obtain
approval from ITR.

Section 1, Overview
1-2 The WindowWasher™ by ITR
1.1 Unpacking The WindowWasher™ by ITR
When you receive The WindowWasher™ by ITR:
1 Unpack it carefully.
2 Check each component against the provided parts list to ensure that
you have everything and that all parts arrived undamaged.
3 If you discover any missing or defective parts, call ITR immediately.
4 If you are not installing The WindowWasher™ by ITR right away,
secure all components so none will be misplaced.
5 Before installing The WindowWasher™ by ITR, read the rest
of Section 1 – Overview. It contains critical information for a
proper installation.
A properly installed WindowWasher™ by ITR is essential for several
reasons:
•To ensure that you and/or your customers receive satisfactory
results.
•To ensure a trouble-free installation, a successful inspection and
testing process and ease of future maintenance.
•To protect your Warranty.
1.2 Protect Your Warranty
This document reflects approved installation techniques, methods, and
materials, and applies only to ITR equipment. The WindowWasher™ by
ITR is only guaranteed by ITR if the entire system has been installed
according to the requirements and recommendations set out here.
Any modification must be approved in writing by qualified ITR
personnel, prior to the installation.
This includes:
•Deviations from the instructions in this Manual.
•Changes to any piece of ITR-supplied equipment.
•Substitution of a non-ITR-approved component.
NOTICE

Section 1, Overview
International Thermal Research 1-3
No warranty will be extended to improper installations. Use of any
unapproved materials, equipment, or installation procedures will result
in a voided warranty for the entire heating system. ITR accepts no
liability for any damage or loss of service resulting from unapproved
modifications.
1.3 The WindowWasher™ by ITR Features
The WindowWasher™ by ITR uses a patented diesel burner (12 VDC)
controlled by a multi-functional electronic controller as the primary
source of heating water. The WindowWasher™ by ITR heats water to
provide a continuous supply for all domestic hot water needs.
Other features of The WindowWasher™ by ITR include:
•A high-temperature, stainless steel burner and stainless steel
jacket.
•5.3 US gallon (20.5 l) welded stainless steel insulated water tank
that minimizes heat loss and optimizes heat recovery.
•Low water level switch in the tank.
•Easy to install with hookups and connections easily accessible
from the top and front of The WindowWasher™ by ITR.
•Quiet operation and low power consumption.
•Low pressure fuel system with built-in fuel pump.
•Fuel efficient burner capable of burning a wide variety of diesel-
based fuels.
•Exhaust has minimal smoke or smell.
•Fan assisted sealed combustion chamber is designed to use
outside air.
•Simple, low amperage draw ignition.
•Electronically-controlled system with:
oAutomatic Safety Shutdown.
oManual reset aquastats for safety overheat protection.
oLED indicators on the Control Panel for diagnostics.
• Efficient
• Clean
• Quiet
• Compact
• Safe
• Rugged
• Reliable
• Economical

Section 1, Overview
1-4 The WindowWasher™ by ITR
oPatented, proprietary flame sensor.
•The WindowWasher™ by ITR Remote Operating Panel with
ON/OFF switch for the diesel burner and indicator LED’s for
operational and diagnostic information.
1.4 Critical Factors
The key factors to keep in mind when planning and carrying out the
installation are:
•Mounting location restrictions for The WindowWasher™ by ITR,
exhaust outlet (to reduce noise, vibration, heat loss, etc.)
•Length, routing, and sizing of fluid lines, fuel lines, air flow tubing,
exhaust piping and wiring.
•Unrestricted intake required to draw in outside air for combustion.
•Ability to easily access and service the product, especially fuel,
plumbing, and electrical systems.
•After installation, requirement to purge water and fuel lines and
inspect/test entire system using the ITR-supplied Inspection
Check Sheet.
1.5 Equipment, Tools and Skills
As the user and/or installer, you must be qualified and authorized to do
the installation, which requires mechanical aptitude and electrical
knowledge. Make sure you comply with existing industry practices,
using the highest and most recent standards and codes. Good
workmanship is essential. Please refer back to Section 1.2, Protect Your
Warranty.
You will need the following equipment and tools (not supplied) to install
the heating system. This list does not include optional equipment and
accessories:
•Standard tools normally available in a well-equipped shop.
•Appropriate fasteners for mounting the heater unit.
Pay attention to the
notices of “Danger”
“Warning” “Caution”
and “Notice” in this
manual.

Section 1, Overview
International Thermal Research 1-5
•Stainless steel 1-1/2” ID exhaust piping, maximum 12’ with no
bends (see Section 3 – Installing the Exhaust System, for details
when bends are present).
•ITR muffler.
•1/4” supply and return fuel line, approved rubber or copper.
•Domestic water hose and/or tubing to connect The
WindowWasher™ by ITR hose fittings to the domestic water
system.
1.6 Testing and Inspection
After all components have been properly installed according to standard
practices, RVIA or ABYC standards, and the recommendations of this
Installation and Operating Manual, The WindowWasher™ by ITR should
be test-operated for inspection purposes.
For your convenience, you can use the pullout Inspection Check Sheet in
this Manual. The Inspection Check Sheet is divided into progressive
sections, allowing each phase of the inspection to be carried out
systematically, and then signed off by authorized persons.

Section 1, Overview
1-6 The WindowWasher™ by ITR

International Thermal Research 2-1
Mounting - The WindowWasher™
2.1 Before You Begin
Plan the location of The WindowWasher™ by ITR and all its major
components in advance to ensure the chosen locations are feasible
and within the technical specifications.
Consider the following factors to help you decide exactly where best
to mount The WindowWasher™ by ITR:
•The WindowWasher™ by ITR weight when full.
•Ventilation requirements.
•Exhaust outlet location and maximum acceptable length.
•Thru hull location.
•Potential for vibration and jarring.
•Fuel storage location.
•Most efficient plumbing runs.
•Safe and convenient access for maintenance.
•Location of other equipment to be installed or connected to
The WindowWasher™ by ITR.
Make sure you are familiar with Section 1 – Overview of this Manual.
If the system is not installed according to specifications and with the
correct equipment, The WindowWasher™ by ITR may not operate
properly, safety may be compromised, and your Warranty may be
voided.
Section
2
!
W
ARNING

Section 2, Mounting The WindowWasher™ by ITR
2-2 The WindowWasher™ by ITR
2.2 Your Mounting Location
Your mounting location should consider the following:
•Mounting location must be able to support double the gross
weight of The WindowWasher™ by ITR (i.e. 150 lbs. x 2 =
300 lbs/68 KG x 2 = 136 KG).
•The WindowWasher™by ITR is 14”H x 14”W x 24”D
(35.6 cm x 35.6 cm x 60.9 cm). See Figure 2-1:
Dimensions.
The WindowWasher™ by ITR must not be installed in any compart-
ment with flammable gases.
•The WindowWasher™ by ITR must be completely isolated
from living spaces. Combustion air must be drawn from a
100% outside source and cannot contain any combustible
gases.
•The WindowWasher™ by ITR must be mounted in an area
that provides unrestricted access to the front panel
mounted fuel and water connections, and top mounted
power and exhaust connection (minimum of 10” top
clearance – top exhaust version; and 3” clearance to all
other WindowWasher™ surfaces.
•The WindowWasher™ by ITR must not be installed in any
compartment with flammable gases.
•The WindowWasher™ by ITR must be mounted horizontal
and level using eight (8) x 1/4” through bolts using 1”
diameter fender washers, lock washers and nuts.
•It is recommended that a catchpan be placed under The
WindowWasher™ by ITR for containing any unexpected
leakage.
If The WindowWasher™ by ITR is going to be mounted in the engine
compartment, check for adequate ventilation. When the engine is
running, this area could be under a negative pressure. Make sure the
air intake and exhaust hoses have no leaks and are well-fastened to
the heater, muffler and thru hull fitting. Assembly parts that may
cause injury through accidental contact should be protected.
! CAUTION
NOTICE

Section 2, Mounting The WindowWasher™ by ITR
International Thermal Research 2-3
Isolate the unit in a closed compartment so that no air from the
heater will infiltrate the vehicle cab.
•Choose a sturdy surface in a location that won’t be unduly
affected by vibration and the jarring of rough roads or rough
seas.
•Mount the unit with the front panel side facing out and
accessible. Facing out simplifies installation and maintenance.
•Open access is required to properly service the heater. Leave
room at the front, and top of the unit.
•Ensure that the exhaust tubing can be properly and safely
routed to the outside. The maximum exhaust run for the
system is 12’.
Figure 2-1: Dimensions
2.3 Procedure
After choosing the mounting location for The WindowWasher™ by ITR:

Section 2, Mounting The WindowWasher™ by ITR
2-4 The WindowWasher™ by ITR
1 Mount The WindowWasher™ by ITR horizontally and level.
2 Secure The WindowWasher™ by ITR in place (against the wall,
floor, or a mounting platform) using eight (8) x 1/4” through bolts
using 1” diameter fender washers, lock washers and nuts (See
Figure 2-2: Location of Mounting Brackets.).
Figure 2-2:Location of Mounting Brackets.
Insets: Bracket/Nut/Bolt Configurations

International Thermal Research 3-1
Installing the Exhaust System
3.1 Before You Begin
For efficient and safe operation of The WindowWasher™ by ITR
follow all recommendations for properly installing the exhaust.
Any deviations from these must be approved in advance by ITR.
Although the heater’s exhaust produces very low carbon
monoxide emissions, caution is still advised:
•Do not operate The WindowWasher™ by ITR in an
enclosed area unless there is adequate ventilation.
•Isolate The WindowWasher™ by ITR in a closed
compartment so that no air from the unit will infiltrate the
living areas.
Never place any exhaust parts close to combustible material or
through a combustible wall or ceiling without fireproof protection.
The exhaust can reach high temperatures.
3.2 Mounting Location
If you can’t meet the technical specifications for mounting the
exhaust, don’t use The WindowWasher™ by ITR. The unit may
perform poorly or become damaged if not installed according to
specifications.
Recommended Exhaust Outlet Locations
The following is recommended for a van exhaust outlet location:
•Mount the exhaust outlet outside the van, not inside the
heater compartment. Otherwise, exhaust fumes could
infiltrate the van from The WindowWasher™ by ITR
compartment.
Section
3
!DANGER

Section 3, Installing the Exhaust System
3-2 The WindowWasher™ by ITR
•In a van, the typical mounting location for the exhaust
outlet is under the floor of the heater compartment, or on
the other side of the van, directly across from the heater
unit. Keep in mind you cannot exceed 12’ of exhaust
piping, including bends.
•Position the outlet of the exhaust pipe so that the exhaust
exits off the side of the van, not towards the front, back,
directly underneath the van, or under an openable
window, vent or sliding door.
Recommendation for Installation
•You may use sweep bends but each 90° bend is equivalent
to two feet of exhaust piping. For example, if you use two
90° bends you must deduct two feet per bend from the
maximum allowed 12’ straight exhaust pipe length.
Therefore you will be restricted to 8’ of straight exhaust
piping plus the two bends. Do not exceed these
recommendations.
•The combustion air-intake must use 100% outside air.
•Use an ITR-manufactured muffler or silencer; no other is
acceptable.
•Exhaust outlet is on the top or bottom of The
WindowWasher™ by ITR, towards the back.
The exhaust and outlet are HOT and the surrounding areas
must be thermally shielded and protected from the hot
surfaces and heat buildup by insulation. Nothing can come
into inadvertent contact with any part of the exhaust system
•Exhaust pipe must have a minimum of 3” (7.6 cm)
clearance from all surfaces.
•Ensure that the exhaust cannot be plugged or restricted.
•The exhaust fitting on The WindowWasher™ by ITR is
1.5” O.D. and the exhaust pipe used must have a
minimum of 1.5” I.D throughout its length.
•All exhaust elbows must be of a large radius design
(minimum radius 2.0”).
! DANGER

Section 3, Installing the Exhaust System
International Thermal Research 3-3
•The exhaust must be supported a minimum of every 3’ of
its installed length.
•The exhaust and The WindowWasher™ by ITR connection
point must use appropriate clamps and sealing compound
to ensure that the connections are tight and leak free. The
WindowWasher™ by ITR exhaust outlet pipe and the
exhaust pipe itself must not be distorted or damaged
during this process.
•With The WindowWasher™ by ITR running, the connection
points and the system must be checked for leaks and any
found must be corrected. Periodically, check the exhaust
fittings, connections, exhaust tube and insulation for leaks
and integrity and correct if required.
•Install an exhaust collar on the exhaust pipe to isolate the
pipe from the van.
What NOT to Do
Don’t mount the exhaust pipe inside the heater compartment.
Don’t use more than 12’ of total exhaust length (including
bends)
Don’t use mufflers with any flow restrictions.
Don’t over tighten exhaust clamps or you may crush The
WindowWasher™ by ITR’s exhaust spout.
3.3 Procedure
Figure 3-1 shows a standard setup for the up exhaust. To install
the exhaust system:
1 Leave suitable air spacing to protect combustible
materials; use an exhaust collar and metal shields where
required.
2 Securely seal the exhaust piping to The WindowWasher™
by ITR fitting using an approved exhaust clamp.
3 Connect the exhaust piping in series with the muffler,
using heavy-duty exhaust clamps. If you use vibration
isolation mounts they must be high temperature.

Section 3, Installing the Exhaust System
3-4 The WindowWasher™ by ITR
4 Connect the air-intake tubing (2” I.D.) to the air-intake
fitting on top of the heater, and to an outside air-intake
fitting or dual thru hull (outside air only). Ensure the run
of tubing is as short as possible to facilitate air flow.
5 Secure both ends of the air-intake tubing with properly
sized hose clamps to prevent air leaks.
6 Make sure the air-intake and exhaust hoses have no leaks
and are not touching each other.
Figure 3-1: Installing the Exhaust System (Up Exhaust)